Isolating deep canal fitting earphone

TECHNICAL FIELD

0001This patent relates to listening devices, and more particularly, to isolating earphones.

BACKGROUND

0002Transducers such as receivers and speakers are useful in many listening devices such as earphones, headphones, Bluetooth wireless headsets, or the like. For instance, a receiver may convert electrical energy received from an audio signal device into acoustic energy and subsequently present the acoustic energy to the eardrum of the user for listening.

0003General speaking, conventional insert earphones are designed to isolate the desired sound presented at the user's ear drum from other sounds and/or noise from the outside environment. In this regard, previous insert earphones typically include a housing having a wide, rigid sound passage tube and a receiver mounted within the housing. A rigid eartip attached around the sound passage tube may be located externally to the housing. When the sound passage tube attached to the housing is inserted into the ear canal of the user, airborne sound moves through the eartip. The eartip engages the walls of the ear canal. In these systems, the receiver within the housing is positioned near the entrance to the ear canal to receive the sound energy.

0004Unfortunately, several problems exist with these previous approaches. For instance, achieving an airtight or otherwise adequate seal in the ear canal is often difficult or impossible. This leads to undesirable sounds (e.g., background noise) entering the ear canal and desirable sounds (e.g., music from an attached listening device) escaping from the ear canal. In addition, these previous devices frequently cause considerable discomfort when worn by the user, due to the hardness of the tube and shape of the eartip. Custom molded earphones have also been attempted, but the manufacture and assembly of these custom molded devices is expensive and labor intensive.

BRIEF DESCRIPTION OF THE DRAWINGS

0005For a more complete understanding of the disclosure, reference should be made to the following detailed description and accompanying drawings wherein:

0006<figref idref="DRAWINGS">FIG. 1</figref> is an exploded view illustrating an earphone according to the present invention;

0007<figref idref="DRAWINGS">FIG. 2</figref> is a perspective view of the earphone of <figref idref="DRAWINGS">FIG. 1</figref> according to the present invention;

0008<figref idref="DRAWINGS">FIG. 3</figref> is a cross-sectional view of the earphone shown in <figref idref="DRAWINGS">FIG. 1</figref> according to the present invention; and

0009<figref idref="DRAWINGS">FIGS. 4 and 5</figref> illustrate full insertion of the earphone of <figref idref="DRAWINGS">FIGS. 1-3</figref> into the ear canal of a user according to the present invention.

0010Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity. It will further be appreciated that certain actions and/or steps may be described or depicted in a particular order of occurrence while those skilled in the art will understand that such specificity with respect to sequence is not actually required. It will also be understood that the terms and expressions used herein have the ordinary meaning as is accorded to such terms and expressions with respect to their corresponding respective areas of inquiry and study except where specific meanings have otherwise been set forth herein.

DETAILED DESCRIPTION

0011While the present disclosure is susceptible to various modifications and alternative forms, certain embodiments are shown by way of example in the drawings and these embodiments will be described in detail herein. It will be understood, however, that this disclosure is not intended to limit the invention to the particular forms described, but to the contrary, the invention is intended to cover all modifications, alternatives, and equivalents falling within the spirit and scope of the invention defined by the appended claims.

0012Isolating earphones using deep canal fittings and approaches for assembling and using these devices are provided. The approaches described herein provide one or more seals to minimize the background noise received by listening devices (e.g., transducers) that are positioned deeply within a user's ear canal. The seal or seals also prevent desirable sounds from escaping from the ear canal. These approaches reproduce sounds with audio fidelity and provide devices that are comfortable for a user to wear. In addition, the devices described herein are easy and cost effective to produce.

0013In many of these embodiments, an insert earphone comprises a housing and at least one transducer that is located in the housing. The transducer is adapted to receive electrical energy and to responsively convert the electrical energy into acoustic energy for presentation to an eardrum of a user. The transducer is positioned within the housing so as to be in close proximity to the eardrum of the user when the housing is inserted into the ear canal. At least one sealing member is coupled to the housing. The sealing member is adapted to provide an acoustic seal within the ear canal of the user.

0014The seal (or seals) provided by the at least one sealing member limit the transmission of sound into the ear canal from outside the ear canal. Consequently, outside sounds do not reach the transducer thereby eliminating or substantially reducing background noise presented to the user's ear drum. Furthermore, the seal or seals also prevent desirable sounds (i.e., those sounds desired to be presented to the ear drum of the user) from escaping from the ear canal. In addition, the earphone is comfortable to wear, provides high audio fidelity, and can be worn by the user over extended periods of time. Since the device is not custom designed or fitted for a particular user, it is cost effective and easy to produce.

0015The sealing member can take a number of different forms. For instance, the sealing member may be a coupling member that is coupled to an outer wall of the housing. In another example, the sealing member is a handle positioned at an end of the housing. In still another example, the sealing member is both a coupling member and a handle. In addition, other structural forms may be used as the sealing member or members.

0016If a coupling member is used, the coupling member may be formed from a number of soft compliant materials such as polyurethane foam, polymers, and silicones. In addition, the transducer may be a single device or multiple devices. For instance, the transducer may be a receiver, conjoined receiver and microphone, or a dual receiver.

0017As mentioned, the insert earphone is inserted into the ear canal of a user in close proximity to the eardrum of the user. If a coupling member is used, the coupling member may be supported substantially entirely or entirely by the ear canal of the user and provide a seal in the ear canal.

0018In others of these embodiments, approaches are provided to insert an earphone into the ear canal of a user. For instance, in one example, at least one transducer is inserted into the ear canal of a user. The transducer is positioned within the ear canal so as to be in close proximity to an eardrum of the user and converts electrical energy into acoustic energy for presentation to the ear drum of the user. At least one acoustic sealing member is positioned outward from the transducer so as to provide an acoustic seal that substantially prevents noise originating outside of the ear canal from entering the ear canal of the user. In addition, desirable noise is retained in the ear canal.

0019Turning now to the drawings and referring now to <figref idref="DRAWINGS">FIG. 1</figref>, an exploded view of an exemplary earphone <b>100</b> is described. The earphone <b>100</b> includes a damper plug <b>102</b>, a bushing member <b>108</b>, at least one transducer <b>118</b>, a pair of wire <b>126</b>, a housing <b>130</b>, a circuit assembly <b>146</b>, a cable <b>154</b>, a handle <b>162</b> (see <figref idref="DRAWINGS">FIG. 2</figref>), and a coupling member <b>182</b>.

0020The transducer <b>118</b> may be a single device or multiple devices. For example, the transducer <b>118</b> may be a receiver, a conjoined receiver and microphone, or a dual receiver. The transducer <b>118</b> comprises a sound outlet tube <b>120</b> and an electrical input terminal <b>122</b> and is operative for generating an acoustic output signal at the sound outlet tube <b>120</b> as a function of an electrical signal applied to the input terminal <b>122</b>.

0021The circuit assembly <b>146</b> may process the electrical signals received. The damper plug <b>102</b> is attached to the sound outlet tube <b>120</b> of the receiver <b>118</b> and the input terminal <b>122</b> of the receiver <b>118</b> is electrically coupled through the wire <b>126</b> to the cable <b>154</b>. Once the receiver <b>118</b> is held in contact with the bushing member <b>108</b>, the damper plug <b>102</b>, and the wire <b>126</b>, the receiver <b>118</b> is positioned within the housing <b>130</b>.

0022The housing <b>130</b> includes an opening <b>132</b>, a body portion <b>134</b>, a tubular portion <b>136</b>, and an annular member <b>138</b>. The annular member <b>138</b> of the housing <b>130</b> is sized to receive the circuit assembly <b>146</b>. One end of the wire <b>126</b> is electrically coupled to the cable <b>154</b> via the circuit assembly <b>146</b>. The handle <b>162</b> is formed of two handle components <b>164</b> and <b>166</b> that snap fit against the housing <b>130</b>. However, it will be understood that the components <b>164</b> and <b>166</b> may be joined together by mechanical fastening, crimping or any other suitable attachment arrangement. The coupling member <b>182</b> mates with the housing <b>130</b>.

0023<figref idref="DRAWINGS">FIG. 2</figref> illustrates a perspective view of the earphone <b>100</b>. The housing <b>130</b> is flexible and may be molded from plastic in one piece and serves the functions of retaining the receiver <b>118</b> mounted to the bushing member <b>108</b> and the wire <b>126</b> (see <figref idref="DRAWINGS">FIG. 1</figref>), supporting the circuit assembly <b>146</b> for connection to the cable <b>154</b>, and supporting the coupling member <b>182</b>. The coupling member <b>182</b> is arranged to conform to the shape of the walls of the ear canal of the user in order to provide an acoustic seal in the ear canal. The coupling member <b>182</b> also provides the main support or the entire support for the earphone <b>100</b> within the ear canal. The coupling member <b>182</b> comprises a soft compliant material such as polyurethane foam, polymer, silicone or a similar material and may be molded from the above-mentioned material in one piece. The coupling member <b>182</b> is disposable after use thereby eliminating the accumulation of ear wax or debris on the coupling member <b>182</b>.

0024The handle <b>162</b> includes at least two holders <b>168</b> and <b>170</b> to provide for removal and replacement of the internal components (e.g., the circuit assembly <b>146</b> or capacitors (not shown)). The handle <b>162</b> is pressed or molded into a shape having a hollow section (not shown) to accommodate the internal components (not shown). The handle <b>162</b> is preferably located at the annular member <b>138</b> of the housing <b>132</b>. In some of these embodiments, the handle <b>162</b> can provide a second seal in addition to the seal provided by the coupling member <b>182</b>. Alternatively, the coupling member <b>182</b> may be omitted and a single seal provided by the handle <b>162</b>.

0025The handle <b>162</b> can be manufactured in a variety of configurations with any desired geometry. More specifically, the handle <b>162</b> includes a first opening <b>174</b> that mates with the tubular portion <b>136</b> of the housing <b>130</b> such that the annular member <b>138</b> of the housing <b>130</b> is securely retained within the handle <b>162</b> by a flange (not shown) and a second opening <b>176</b> to receive the cable <b>154</b>. The handle <b>162</b> comprises a rigid and durable material such as polypropylene (pp) or a similar material (e.g., a polymer) and may be molded in one piece or more pieces.

0026<figref idref="DRAWINGS">FIG. 3</figref> illustrates a cross-sectional view of the exemplary earphone <b>100</b> in conjunction with an exemplary method of assembling the earphone <b>100</b>. As discussed earlier, the receiver <b>118</b> is mounted against the bushing member <b>108</b> and a filler <b>124</b> such as cement or a similar material is applied to fill the gap of the hollow section of the bushing member <b>108</b> and around the sound outlet tube <b>120</b> of the receiver <b>118</b>. In one example, the bushing member <b>108</b> is pressed or molded from plastic in one piece. The damper plug <b>102</b> in the form of a tube shape may be made of stainless steel and is oriented according to the side wall of the bushing member <b>108</b>, until the sound outlet tube <b>120</b> of the receiver <b>118</b> butts up against the side wall of the damper plug <b>102</b> to allow the acoustic signal travel to the ear canal.

0027A dust guard or acoustic resistor may be made of cloth or felt is attached within the damper plug <b>102</b> by any suitable method of attachment provides an acoustical resistance to the receiver <b>118</b> and prevents debris or ear wax from entering the receiver, which may damage the working components contained within the receiver <b>118</b>. The damper plug <b>102</b> is preferably disposable and replaceable when clogged with ear wax or otherwise defective. The receiver <b>118</b> that is mounted to the bushing member <b>108</b> is retained in a first chamber <b>140</b> of the housing <b>130</b>.

0028One end of the wire <b>126</b> is electrically coupled to the input terminal <b>122</b> of the receiver <b>118</b> and the other end of the wire <b>126</b> is electrically coupled to the connections <b>150</b> of the circuit assembly <b>146</b>. A slack of wire (not shown) may be provided to prevent tension in the wire. As shown, the wire <b>126</b> is retained in a second chamber <b>142</b> of the housing <b>130</b> wherein the second chamber <b>142</b> is formed in the tubular portion <b>136</b> of the housing <b>130</b>. The dimensions of the second chamber <b>142</b> are preferably smaller than or equal to the dimensions of the first chamber <b>140</b>. The circuit assembly <b>146</b> includes a circuit board <b>152</b>, a hole <b>148</b>, and a plurality of connections <b>150</b>. Optional components (not shown) such as capacitors may be mounted to the circuit board <b>152</b> serve to reduce RF interference.

0029The circuit board <b>152</b> may be formed in various shapes and sizes corresponding to the annular member <b>138</b> of the housing <b>130</b> or otherwise according to the requirements of specific applications. The front surface of the circuit board <b>152</b> may have printed wiring traces.

0030As mentioned earlier, the second end of the wire <b>126</b> is mounted to the front surface of the circuit board <b>152</b> via the hole <b>148</b>. The cable <b>154</b> is electrically coupled to the front surface of the circuit board <b>152</b> to provide connection to the receiver <b>118</b> via the wire <b>126</b>.

0031Electrical signals representative of sound are transmitted by cable <b>154</b>, a wire <b>158</b>, circuit assembly <b>146</b>, and the wire <b>126</b> to the receiver <b>118</b> from an audio signal device (not shown). The audio signal devices may be cellular phones, MP3 players or any other type of device that provides audio signals in electrical form. A strain relief (not shown) is affixed to the cable <b>154</b> with glue or any other suitable means for anchoring the cable <b>154</b> within the handle <b>162</b>.

0032In the embodiment shown, a cable knot <b>156</b> is provided to anchor the cable <b>154</b> within the handle <b>162</b>. The front surface of the circuit assembly <b>146</b> is held in contact with a plurality of flanges <b>172</b> formed within the inner surface of the handle <b>162</b> by any suitable from of attachments.

0033As shown in <figref idref="DRAWINGS">FIG. 3</figref>, the hole <b>148</b> is aligned with the second chamber <b>142</b> of the housing <b>130</b>. When all the components are placed in final or closed position, the first and second handles <b>164</b>, <b>166</b> are snap fit against the housing <b>130</b> and the cable <b>154</b>. More specifically, the opening <b>174</b> of the handle <b>162</b> engages the annular member <b>138</b> of the housing <b>130</b> and the second opening <b>176</b> of the handle <b>162</b> engages the strain relief <b>156</b> of the cable <b>154</b>. The coupling member <b>182</b> is provided on the outer portion of the housing <b>130</b>. More specifically, an inner portion <b>186</b> of the coupling member <b>182</b> is affixed to the outer portion of the tubular portion <b>136</b> or the body portion <b>134</b> or both the body and tubular portions <b>134</b>, <b>136</b> with glue or any other suitable means. An outer portion <b>184</b> of the coupling member <b>182</b> is positioned to come into contact with the walls of the ear canal of the user.

0034<figref idref="DRAWINGS">FIGS. 4-5</figref> illustrate examples of full insertion of the exemplary earphone <b>100</b> into an ear canal <b>190</b> of a user. The earphone <b>100</b> (connected to the cable <b>154</b>) is fully inserted into the ear canal <b>190</b> of a user, in close proximity to the user's eardrum <b>192</b>, such that the coupling member <b>182</b> conforms to the inner walls of the ear canal <b>190</b>. The coupling member <b>182</b> is supported entirely or substantially entirely by the ear canal <b>190</b> to provide a seal limiting transmission of sound to the ear canal <b>190</b>. The earphone <b>100</b> (including the coupling member <b>182</b>) is inserted and positioned in the ear canal <b>190</b> such that the eardrum <b>192</b> can easily receive acoustic energy from the earphone <b>100</b>.

0035In <figref idref="DRAWINGS">FIG. 4</figref>, the coupling member <b>182</b> is coupled to the tubular portion <b>136</b>. The earphone <b>100</b> provides a comfortable fit in the user's ear canal <b>190</b> and yet provides a good seal to reduce or eliminate noise from outside the ear from reaching the ear canal <b>190</b> and/or the transducer within the earphone <b>100</b>. In addition, desirable sounds are prevented from escaping from the ear canal <b>190</b>. The seal that is formed may be airtight or substantially airtight.

0036In an alternate embodiment shown in <figref idref="DRAWINGS">FIG. 5</figref>, the coupling member <b>182</b> conforms to the inner wall of the ear canal <b>190</b> and is affixed to the outer portion of the body portion <b>134</b>. The coupling member <b>182</b> provides an airtight seal or substantially airtight seal in the ear canal <b>190</b>. The seal limits the transmission of sound into the ear canal from outside the ear canal <b>190</b>. In this example, a second seal is provided by the handle <b>164</b> as the handle fits snuggly against the end of the ear canal <b>190</b>. Consequently, the outside sounds do not reach the transducer thereby eliminating or substantially eliminating background noise. Furthermore, desirable sounds are prevented from escaping from the ear canal <b>190</b>. In addition, the earphone <b>100</b> is comfortable to wear, provides high audio fidelity, and can be worn by the user over extended periods of time.

0037The examples of <figref idref="DRAWINGS">FIGS. 4 and 5</figref> show the coupling member <b>182</b> either coupled to the tubular portion <b>136</b> or the body portion <b>134</b>. However, it will be understood that the coupling member <b>182</b> may be coupled to both portions <b>134</b> and <b>136</b>. Furthermore, the coupling member <b>182</b> may take any form, and, for example, may be comprised of multiple portions or segments. Moreover, while some of the above-mentioned examples may use both a coupling member and a handle to provide a seal, one of these components may be omitted.

0038In addition, while the earphone <b>100</b> is positioned in close proximity to the eardrum <b>192</b> (such that the eardrum <b>192</b> can easily receive acoustic energy from the earphone <b>100</b>), the exact dimensions of the ear canal <b>190</b> and ear drum <b>192</b> of a particular user may affect the exact positioning of the earphone <b>100</b>, the coupling member <b>182</b>, and the seal (or seals) formed by the coupling member <b>182</b> (and any handle or other sealing component).

0039Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. It should be understood that the illustrated embodiments are exemplary only, and should not be taken as limiting the scope of the invention.